ELPRO 415U-2 User manual

Brand: ELPRO

Model: 415U-2

Category: Networking

Type: User manual

This manual is also suitable for

User Manual MN032006EN

Effective May 2018

New information

415U Condor-long-range

wireless I/O and gateway

Version 2.20

User Manual MN032006EN

Effective May 2018

415U Condor-long-range

wireless I/O and gateway

EATON www.eaton.com

Product Notices

ATTENTION

INCORRECT TERMINATION OF SUPPLY WIRES MAY CAUSE INTERNAL

DAMAGE AND WILL VOID THE WARRANTY. TO ENSURE THAT YOUR

415U-2 WIRELESS I/O AND GATEWAY ENJOYS A LONG LIFE, CHECK THIS

USER MANUAL TO VERIFY THAT ALL CONNECTIONS ARETERMINATED

CORRECTLY BEFORE TURNING ON POWER FOR THEFIRST TIME.

Safety notices

Exposure to RF energy is an important safety consideration. The

FCC has adopted a safety standard for human exposure to radio

frequency electromagnetic energy emitted by FCC regulated

equipment as a result of its actions in Docket 93-62 and OET

Bulletin65 Edition 97-01.

CAUTION

TO COMPLY WITH FCC RF EXPOSURE REQUIREMENTS IN SECTION 1.1310

OF THE FCC RULES, ANTENNAS USED WITH THIS DEVICE MUST BE

INSTALLED TO PROVIDE A SEPARATION DISTANCE OF AT LEAST 20 CM

FROM ALL PERSONS TO SATISFY RF EXPOSURE COMPLIANCE.

DO NOT OPERATE THE TRANSMITTER WHEN ANYONE IS WITHIN 20 CM OF

THE ANTENNA. ENSURE THAT THE ANTENNA IS CORRECTLY INSTALLED IN

ORDER TO SATISFY THIS SAFETY REQUIREMENT.

Avoid

•

Operating the transmitter unless all RF connectors are secure

andany open connectors are properly terminated

•

Operating the equipment near electrical blasting caps or in an

explosive atmosphere

Note: All equipment must be properly grounded for safe

operations. Allequipment should be serviced only by a

qualifiedtechnician.

FCC notice

Part 15.19—This device complies with part 15 of the FCC rules.

Operation is subject to the following two conditions: (1) this device

may not cause harmful interference, and (2) this device must accept

any interference received, including interference that may cause

undesired operation.

Part 15.21—The grantee is not responsible for any changes or

modifications not expressly approved by the party responsible for

compliance. Such modifications could void the user’s authority to

operate the equipment.

Part 15.105(b)—This equipment has been tested and found to

comply with the limits for a Class B digital device, pursuant to

part 15 of the FCC Rules. These limits are designed to provide

reasonable protection against harmful interference in a residential

installation. This equipment generates, uses and can radiate radio

frequency energy and, if not installed and used in accordance

with the instructions, may cause harmful interference to radio

communications. However, there is no guarantee that interference

will not occur in a particular installation. If this equipment does

cause harmful interference to radio or television reception, which

can be determined by turning the equipment off and on, the user is

encouraged to try to correct the interference by one or more of the

following measures:

•

Reorient or relocate the receiving antenna

•

Increase the separation between the equipment and receiver

•

Connect the equipment into an outlet on a circuit different from

that to which the receiver is connected

•

Consult the dealer or an experienced radio/TV technician for help

Part 90—This device has been type accepted for operation by the

FCC in accordance with Part 90 of the FCC rules (47CFR Part 90).

See the label on the unit for the specific FCC ID and any other

certification designations.

Note: This device should only be connected to PCs that are

covered by either a FCC DoC or are FCC certified.

Manufacturer Model number Coax kit Net

ELPRO UDP400-C CC3/450 1 dB gain

ELPRO BU-3/400 CC10/450 2.5 dB gain

ELPRO BU-6/400 CC10/450 5.5 dB gain

ELPRO YU3/400 CC10/450 3.5 dB gain

ELPRO YU6/400 C10/450 6.5 dB gain

ELPRO YU9/400 CC20/450 5 dB gain

ELPRO YU16/400 CC20/450 10 dB gain

Hazardous location notices

The 415U-2-C4-EX, 415U-2-C3-EX, 415U-E-C4-EX and 415U-E-C3-EX

comply with the following standards:

•

IEC 60079-0:2012/A11:2013

•

IEC 60079-15:2010

The 415U-2-C4-EX, 415U-2-C3-EX, 415U-E-C4-EX and

415U-E-C3-EX comply with Directive 2014/34/EU—ATEX

Directive ExnA IIC T4 Gc –40 °C ≤ Ta ≤ +70 °C.

Special conditions

1) This equipment is designed to be installed as a

component in anenclosure that meets IP54.

2) This equipment is to be mounted in a vertical orientation

to facilitate effective heat dissipation.

WARNING: EXPLOSION HAZARD

DO NOT DISCONNECT EQUIPMENT UNLESS POWER HAS BEEN SWITCHED

OFF OR THE AREA IS KNOWN TO BE NON-HAZARDOUS.

The 415U-2-C4-EX, 415U-2-C3-EX, 415U-E-C4-EX and

415U-E-C3-EX are suitable for use in Class 1, Division2,

Groups A, B, C and D; Tamb –40° C to +70° C or

non-hazardous locations only.

This equipment shall be installed in accordance with

the requirements specified in Article 820 of the National

Electrical Code (NEC), ANSI/NFPA 70-2011. Section 820.40

of the NEC provides guidelines for proper grounding, and

in particular specifies that the antenna ground (shield) shall

be connected to the grounding system of the building, as

close to the point of cable entry as practical.

This equipment shall be installed in a restricted access

location, such as a dedicated equipment room or

service closet.

The earth/ground terminal of this equipment shall be

connected to earth ground in the equipment installation.

The external power supply installed with this equipment

shall be a listed, Class 2 power supply, with a rated output

between 15 Vdc and 30 Vdc, and minimum 3500 mA.

General Notices

ELPRO products are designed to be used in industrial environments

by experienced industrial engineering personnel with adequate

iii

User Manual MN032006EN

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EATON www.eaton.com

knowledge of safety design considerations.

ELPRO products use communications channels that are subject to

noise and interference. The products are designed to operate in the

presence of noise and interference, but in an extreme case noise

and interference can cause product operation delays or operation

failure. Like all industrial electronic products, ELPRO products can

fail in a variety of modes due to misuse, age, or malfunction. We

recommend that users and designers design systems using design

techniques intended to prevent personal injury or damage during

product operation, and provide failure tolerant systems to prevent

personal injury or damage in the event of product failure. Designers

must warn users of the equipment or systems if adequate

protection against failure has not been included in the system

design. Designers must include this Important Notice in operating

procedures and system manuals.

These products should not be used in non-industrial applications, or

life-support systems, without first consulting Eaton.

To avoid accidents during maintenance or adjustment of remotely

controlled equipment, all equipment should be first disconnected

from the 415U module during these adjustments. Equipment should

carry clear markings to indicate remote or automatic operation. For

example: “This equipment is remotely controlled and may start

without warning. Isolate at the switchboard before attempting

adjustments.”

The 415U modules are not suitable for use in explosive

environments without additional protection.

The 415U modules operate proprietary protocols to communicate.

Nevertheless, if your system is not adequately secured, third parties

may be able to gain access to your data or gain control of your

equipment via the radio link. Before deploying a system, make sure

that you have carefully considered the security aspects of your

installation.

Follow instructions

Read this entire manual and all other publications pertaining to the

work to be performed before installing, operating, or servicing this

equipment. Practice all plant and safety instructions and precautions.

Failure to follow the instructions can cause personal injury and/or

property damage.

Proper use

Any unauthorized modifications to or use of this equipment outside

its specified mechanical, electrical, or other operating limits may

cause personal injury and/or property damage, including damage to

the equipment. Any such unauthorized modifications: (1) constitute

“misuse” and/or “negligence” within the meaning of the product

warranty, thereby excluding warranty coverage for any resulting

damage; and (2) invalidate product certifications or listings.

Product disposal

When your product reaches the end of its useful life, it is important

to take care in the disposal of the product to minimize the impact on

the environment.

General instructions

The product housing is made of die-cast aluminum

(aluminium) andmay be recycled through regular metal

reclamation operators inyour area.

The product circuit board should be disposed according to your

country’s regulations for disposing electronics equipment.

Europe

In Europe, you can return the product to the

place of purchase to have the product disposed in

accordance with EU WEEE legislation.

Deployment of Eaton products in customer environment

There is increasing concern regarding cybersecurity across

industries, where companies are steadily integrating field devices

into enterprise-wide information systems. This is why Eaton

has incorporated secure development life cycle in their product

development to ensure that cybersecurity is addressed at all levels

ofdevelopment and commissioning of our products.

There is no protection method that is completely secure.

Industrial Control Systems continue to be the target for attacks.

The complexities of these attacks make it very difficult to have a

complete secure system. A defense mechanism that is effective

today may not be effective tomorrow as the ways and means

of cyber-attacks constantly change. Therefore it’s critical that our

customers remain aware of changes in cybersecurity and continue

to work to prevent any potential vulnerability of their products and

systems in their environment.

At Eaton we are focusing on analyzing emerging threats and

ensuring that we are developing secure products and helping

our customers deploy and maintain our solutions in a secure

environment. We continue to evaluate cybersecurity updates that

webecome aware of and provide the necessary communication

onour website as soon as possible.

Eaton strongly recommends our customers to apply the deployment

practices that are outlined in the appendix to this document -

“Secure hardening guidelines” on page 74.

Release notice

This is the update release of the 415U Wireless I/O and Gateway

User Manual version 2.20, which applies to configuration software

version 2.1.0.10 and firmware version 2.20. This user manual covers

models 415U-2-C and 415U-E-C and Hazardous Location models

415U-2-C-EX and 415U-2-E-C-EX.

Documentation note

Eaton acquired Cooper Industries in November, 2012. “Cooper

Bussmann” may appear in some screen images within this guide.

GNU General public license

Eaton is using a part of Free Software code under the GNU General

Public License in operating the 415U products. This General Public

License applies to most of the Free Software Foundation’s code and

to any other program whose authors commit by using it. The Free

Software is copyrighted by Free Software Foundation, Inc., and the

program is licensed “as is” without warranty of any kind. Users are

free to contact Eaton at the following web address: www.eaton.

com/wireless for instructions on how to obtain the source code used

for the 415U.

A copy of the license is included in GNU Free Document License at

the end of the manual.

User Manual MN032006EN

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415U Condor-long-range

wireless I/O and gateway

EATON www.eaton.com

Table of contents

Product Notices ....................................... ii

Safety notices ...................................... ii

FCC notice ......................................... ii

Hazardous location notices ............................ ii

General Notices ..................................... ii

Deployment of Eaton products in customer environment ......

iii

Introduction .......................................... 1

Overview .......................................... 1

Module structure .................................... 2

Getting started ........................................ 2

Installation ........................................... 3

General ............................................ 3

Thermal ........................................... 3

Power Supply ....................................... 5

Internal I/O ........................................ 6

Grounding .......................................... 6

Radio ............................................. 6

Antennas .......................................... 6

Connections ........................................ 8

Side access configuration panel ........................ 8

Front panel connections ............................. 10

Digital or pulsed inputs .............................. 10

Digital outputs (pulsed outputs) ........................ 10

Analog inputs ...................................... 11

Analog outputs ..................................... 12

System design ....................................... 13

Design for failures .................................. 13

Testing and commissioning ........................... 13

Networking modes ................................. 13

IP Address assignment .............................. 15

Network traffic control in bridged networks .............. 15

Radio Paths and Data Rate ........................... 16

Configuration ........................................ 17

Connecting using the Configuration Utility ............... 17

Configuring your System using CConfig Utility ............ 18

Configure how the device connects .................... 18

Networking ........................................ 20

Mappings ......................................... 21

Fail-safe blocks ..................................... 28

Sensitivity blocks ................................... 29

Dashboard configuration ............................. 30

Serial configuration ................................. 32

Modbus configuration ............................... 34

DNP3 protocol configuration .......................... 39

Advanced port settings .............................. 40

I/O configuration ................................... 40

Analog inputs ...................................... 42

Configuring using the web configuration utility ............. 44

Connecting to the embedded web configuration .......... 44

Configuring the locale ............................... 45

Quick start—basic device configuration .................. 46

Default Back-To-Back gather scatter mapping ............. 48

Module information web page ......................... 49

System tools ...................................... 49

Feature license keys ................................. 51

Changing your password ............................. 51

User management .................................. 52

Advanced network configuration ......................... 53

Network .......................................... 53

Radio ............................................ 54

Advanced Radio Configuration ......................... 55

Repeaters ......................................... 56

IP Routing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

DHCP Server ...................................... 57

VLAN Configuration ................................. 57

Logic Configuration ................................. 58

Diagnostics ......................................... 59

IO diagnostics ..................................... 59

Expansion I/O error registers .......................... 60

Diagnostic registers—device statistics .................. 60

Monitoring communications .......................... 61

Data logging ....................................... 62

Specifications ....................................... 64

Troubleshooting ...................................... 65

Restoring the factory default settings ................... 65

Configuring PC networking settings .................... 65

LED function ........................................ 66

Front panel LEDs ................................... 66

Additional 415U-E LEDs .............................. 66

LED boot sequence ................................. 66

Input and output LEDs ............................... 67

Ethernet LEDs ..................................... 67

Physical I/O registers ................................ 70

Expansion I/O registers .............................. 71

Device models and locales ............................. 72

Modbus error codes .................................. 73

Secure hardening guidelines ............................ 74

Full firmware upgrade ................................. 76

IO Plus Logic Command Reference ...................... 79

GNU General public license ............................ 81

Glossary ............................................ 83

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Introduction

Overview

The ELPRO 415U Ethernet Networking I/O and Gateway is a multiple

I/O node that extends communications to sensors and actuators in

local, remote, or difficult to reach locations. Designed to work with

wired and wireless devices, the ELPRO 415U is capable of providing

IP-based I/O across sprawling industrial environments typical of

industrial applications.

The 415U can serve as an end node or network gateway andis

scalable to thousands of nodes. Gather-scatter and block mapping

technology offers the efficient use of network resources, allowing

point-to-point transfer of process signal within complex monitoring

and control systems. Integrated Modbus

server capability allows

further I/O expansion through the use of ELPRO 115S expansion

modules.

The module can monitor the following types of signals:

•

Digital (on/off) signals, such as a contact closure or switch

•

Analog (continuously variable) signals, such as tank level, motor

speed, or temperature

•

Pulsed signal, frequency signals, such as metering, accumulated

total, or rainfall

•

Internal signals, such as supply voltage, supply failure, or

battery status

The modules monitor the input signals and transmit the values

by radio or Ethernet cabling to another module (or modules) that

have been configured to receive this information. The 415U radio

is available in models to support both unlicensed and licensed

operation depending on your country.

Input signals that are connected to the module are transmitted and

appear as output signals on other modules. A transmission occurs

whenever a change of state (COS) occurs on an input signal. A COS

of a digital or an internal digital input is a change from “off” to “on,”

or a change from “on” to “off.” For an analog input, internal analog

input, or pulse input rate, a COS is a configurable value referred

to as sensitivity. The default sensitivity is 1000 counts (3%), but

you can change this value using the sensitivity block configuration

pagein the CConfig utility, as described in “Configuration” on page

17.

In addition to COS messages, update messages are automatically

transmitted on a configurable time basis. These updates ensure

system integrity. Pulse inputs counts are accumulated and the

totalcount is transmitted regularly according to the configured

update time.

The 415U modules transmit the input/output data using radio or

Ethernet. The data frame includes the address of the sending

module and the receiving module, so that each transmitted message

is acted upon only by the correct receiving unit. Each message

includes error checking to ensure that no corruption of the data

frame has occurred due to noise or interference. The module with

the correct receiving address will acknowledge the message with a

return transmission (acknowledgment). If the original module does

not receive a correct acknowledgment, it will retry multiple times

before setting the communications status of that message to “fail.”

For critical messages, this status can be reflected on an output on

the module for alert purposes. The module will continue to try to

establish communications and retry each time an update or

COS occurs.

The 415U comes from the factory with ELPRO WIB, Modbus

TCP/RTU and DNP3 protocols as standard. WIB protocol provides

powerful enhanced features, including IP addressing and it allows

thousands of modules to exist in a system. Modbus TCP and DNP3

protocols provide a standards-based interface to a multitude of

commercially available controls systems, including PLCs, DCS,

andSCADA.

A system can be a complex network or a simple pair of modules.

Aneasy-to-use configuration procedure allows you to specify any

output destination for each input. Each 415U device can have up

to 19 expansion I/O modules (ELPRO 115S) connected by RS-485

twisted pair cable. Any input signal at any module may be configured

to appear at any output on any module in the entire system.

The units can be configured using the CConfig utility via Ethernet,

remotely over the radio, or USB. Advanced users may configure the

units by accessing the internal Web pages using a Web browser.

TheCConfig utility is described in “Configuration” on page 17.

For Web-based configuration, see “Configuring using the web

configuration utility” on page 44.

ote:N 415U Series product versions

In August 2017, we extended the 415U product range with the

introduction of the 415U Condor series. These modules support

wider temperature range, higher radio transmit power and faster

radio throughput. These products are compatible with earlier

415U-2-H and 415U-2-L products, but have different thermal

requirements. Refer to the separate Manual MN032002EN for

detail of the earlier 415U-2-H and 415U-2-L products.

Model code Description Details

415U-2-L-FFF-B First Generation. Low power

radio 10-500mW

Suitable for Hazardous

Locations

No Thermal De-rating required.

Operating temp -30°C to +60°C

IEC Ex / ATEX Zone 2

UL Class 1 Div 2

415U-2-H-FFF-B First Generation. High power

radio 500mW - 5W

Refer 415U-2-H user manual

MN032002EN for De-rating

charts

Operating temp -30°C to +60°C

415U-2-CF Second Generation 415U. High

power radio 10mW - 10W

Refer to thermal De-rating

charts in this manual.

Operating temp -40°C to +70°C

415U-E-CF Second Generation 415U. High

power radio 10mW - 10W.

Modem version with Reduced

I/O count

Refer De-rating charts in this

manual.

Operating temp -40°C to +70°C

415U-2-CF-EX Second Generation 415U-2.

Reduced radio power 10mW

- 2W

Suitable for Hazardous

Locations

Refer De-rating charts in this

manual.

Operating temp -40°C to +70°C

IEC Ex / ATEX Zone 2

UL Class 1 Div 2

415U-E-CF-EX Second Generation 415U.

Reduced radio power 10mW

- 2W. Modem version with

Reduced I/O count

Suitable for Hazardous

Locations

Refer De-rating charts in this

manual.

Operating temp -40°C to +70°C

IEC Ex / ATEX Zone 2

UL Class 1 Div 2

FFF Frequency Band for first Generation – Indicates the Center of

20MHz tuning band

B Modulation Bandwidth for first Generation W – 25kHz, N – 12.5kHz

F Frequency Band for Second Generation product. –C3 indicates 340

to 400Mhz tuning band. –C4 indicates 400 to 480MHz tuning band.

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Module structure

The 415U module is made up of different interface areas with a

central input and output storage area (I/O store). The I/O store is

an area of memory made available for the status of the physical

on-board I/O and internal I/O registers. It also provides services for

other processes within the module.

The I/O store is split into eight different block types:

•

Two blocks made available for bit data (discrete)

•

Two blocks made available for word data (analog)

•

Two blocks made available for 32-bit words data (counters)

•

Two blocks made available for floating point data (analogs)

Each of these block types in turn support input and output locations

that can interface with the physical I/O on the local machine

and also be used for data storage when used as a gateway to

external devices. These block type locations are illustrated in

Figure 1 and are described in “Register memory map” on page

68.

There are other registers within the database that can be used for

system management.

Figure 1. Module structure

The radio and Ethernet interfaces (see Figure 1) allow the 415U

to communicate with other modules within the system using a

proprietary protocol called WIB. I/O Messages from other 415U

modules are received on the communication ports and then passed

to the I/O store which will in turn update the register locations

accordingly. The WIB protocol is designed to provide reliable

communications suitable for an Ethernet channel or for an open

license-free radio channel. It is an extremely efficient protocol

for radio communications because the messages are sent using

exception reporting (only transmitting when there is a change of

an input signal) rather than transmitting all of the time. Update

messages can also be configured at a predetermined time for

integrity checks.

Each message can be comprised of multiple I/O values, referred

to as a “block of I/O.” The messages use error checking and return

acknowledgment for greater reliability. Up to four attempts are made

when transmitting the message over each hop of the radio path, and

if no acknowledgment is received a Comms indication can

be flagged.

The on-board I/O includes eight discrete I/O, two single-ended

analog inputs, two differential analog inputs, and two current

sourcing analog outputs. Each discrete I/O can function as either

a discrete input (voltage-free contact input) or discrete output

(transistor output). Each I/O point is linked to separate I/O registers

within the I/O data store.

The following internal I/O can be accessed from the I/O store. The

inputs can be used to interpret the status of a single module or an

entire system:

•

Battery voltage—The battery terminal voltage, displayed as an

analog value.

•

Loop supply—The +24 Vdc analog loop supply (ALS) used to

power analog current loops, displayed as an analog value.

•

Expansion module volts—The supply voltage of the connected

expansion modules, displayed as an analog value.

•

RSSI—The radio signal level for the selectable address, reported

as a dB level.

•

Comms Fail—A selectable register can indicate a

Communications Fail error for a particular message transmission.

The expansion port, allows 115S expansion I/O modules to be added

to the module. Expansion I/O is dynamically added to the internal I/O

of the 415U module by adding an offset to the address.

Getting started

Most applications for the 415U module require little configuration.

The 415U has many sophisticated features, but if you do not

require these features you can use this section to configure the

units quickly.

To get started quickly:

1. Read “Installation” on page 3, which describes the power

supply, antenna/coax connections, and I/O connections.

2. Power on the 415U module and set up a USB connection to

your PC. For detailed steps, see “Connecting using the

Configuration Utility” on page 17.

3. Install and run the CConfig utility. For CConfig installation

instructions, see “Downloading and installing CConfig” on page

17.

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Installation

General

The 415U Series modules are housed in a aluminum enclosure with

DIN rail mounting, providing options for up to 14 I/O points, and

separate power and communications connectors. The enclosure

measures 6.7”x5.9”x1.6” (170mm x 150mm x 40mm), including

the connectors. The antenna protrudes from the top.

Thermal

The 415U series modules contain a high-power radio that can

generate a significant amount of heat.

For effective heat dissipation, the device must be mounted in

the vertical orientation, with the antenna connection at the top,

and with clearance of at least 25 mm on the right side to allow

thermal convection.

When multiple circuits are active at the same time (Expansion I/O,

On-Board I/O, Battery Charging, Radio Transmit), and when powered

from the “SUP” inputs, the 415U can overheat if it is also operating

at the high end of the allowed temperature range.

If your radio transmitter will be operating in a high-duty cycle mode

(for example a repeater or base-station) you must check the de-rating

charts below to ensure the radio will be able to operate continuously

at your expected ambient temperature.

You can calculate the expected duty cycle of your device by

calculating the expected number of messages and the expected

message duration, or you can check the duty cycle once the system

is p and running (Network Diagnostics >> Custom Survey >> All Tx

Frames).

If the device will be outside it’s thermal operating limit at the

designed duty cycle, you can either reduce the transmit power, or

you can power the device from a 13.8V supply through the BAT+

and GND terminals.

415U-2-C and 415U-E-C Power level and modulation

The charts below show the radio power relative to the maximum

radio power for the 415U-2-C and 415U-E-C models. The maximum

radio power depends on the radio modulation mode selected.

Refer to Table 1 below to relate power level, modulation and the

power levels on the charts shown on the following pages.

Legacy compatability (FSK)

BandWidth Data rate Max Tx Power Max -2dB Max -3dB Max -6dB

12.5kHz, 25kHz All 40dBm 38dBm 37dBm 34dBm

High speed mode (QAM)

BandWidth Data rate Max Tx power Max -2dB Max -3dB Max -6dB

6.25kHz 4k,8k 36dBm 34dBm 33dBm 30dBm

16k,24k 34dBm 32dBm 31dBm 28dBm

12.5kHz 8k,16k 36dBm 34dBm 33dBm 30dBm

32k,48k 34dBm 32dBm 31dBm 28dBm

6.25kHz 16k,32k 36dBm 34dBm 33dBm 30dBm

64k,96k 34dBm 32dBm 31dBm 28dBm

Table 1

Thermal Derating Charts for 415U-2-C and 415U-E-C

operating from SUP inputs

Figure 2. 415U Worst case.

The worst case occurs when you are using all features of the 415U-

2-C at maximum.

•

Operating from the SUP+ and SUP- inputs

•

All On-Board I/O circuits at maximum (analogs at 20mA, digital

outputs at 200mA load)

•

115S modules connected to the “Expansion” port operating at

maximum rated current (500mA).

•

Battery Charging at full rate (SLA battery recharging after

extended power outage on BAT+ / GND terminals)

•

Use the de-rating chart above to limit the radio power and duty

cycle depending on the expected maximum temperature.

ote:N When operating from supply voltage 17V or below and at maximum

ransmit power, you need to apply the additional derating shown.

Figure 3. 415U-2-C Battery Charging and onboard I/O.

As above, except without 115S Expansion I/O.

•

Operating from the SUP+ and SUP- inputs

•

All On-Board I/O circuits at maximum (analogs at 20mA, digital

outputs at 200mA load)

•

Battery Charging at full rate (SLA battery recharging after

extended power outage)

•

Use the de-rating chart above to limit the radio power and duty

cycle depending on the expected maximum temperature.

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Figure 4. 415U-2-C Onboard I/O only.

As figure 3, except without the need to charge an SLA battery.

•

Operating from the SUP+ and SUP- inputs

•

All On-Board I/O circuits at maximum (analogs at 20mA, digital

outputs at 200mA load)

•

115S modules connected to the “Expansion” port operating at

maximum rated current (500mA).

•

Use the de-rating chart above to limit the radio power and duty

cycle depending on the expected maximum temperature.

Figure 5. 415U Radio only.

Use this chart when operating without active I/O, and without the

need to charge an SLA battery.

•

Operating from the SUP+ and SUP- inputs

•

All On-Board I/O circuits unused

•

Use the de-rating chart above to limit the radio power and duty

cycle depending on the expected maximum temperature.

ETHERNET

USB RS232 SUPPLY

GND

BAT SUP

SUP

B A

15-30 Vdc

Supply

3A Fuse

Optional

10.8–15 Vdc

Lead Acid

Battery

–

Figure 6. Supply connections

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Power Supply

The 415U-2-C and 415U-E-C will operate from a 15–30 Vdc supply

(nominal 24 Vdc) connected to the SUP+ and SUP– terminals. It will

charge a 13.8V sealed lead acid (SLA) battery connected to the BAT+

and GND terminals, and operate from this battery if the main supply

fails..

Powering from the SUP+ and SUP– terminals

The power supply on the SUP+ and SUP– terminals must be able

to supply enough current to operate the device, to power all of

the I/O circuits connected to the 415U, and to power the device’s

radio transmitter when it is sending data. A 24 Vdc 2.5 A power

supply such as PS-DINAC-24DC-OK is suitable for all configurations,

including configurations requiring battery charging and expansion I/O.

If you need to use a supply with a lower power rating; or if you

need to power additional equipment in your installation; use these

guidelines to determine your required power supply current. Add

the relevant elements from Table 2 to determine your power supply

current requirement. Remember you also need to add current for

any other equipment being powered from the same power supply,

including relays, loop isolators, indicators, etc.

Table 2. Power supply current requirements

Supply voltage

17 Vdc 24 Vdc 30 Vdc

Base operating current 180 mA 140 mA 100 mA

Radio transmit current

10W FSK 2100 mA 1300 mA 1100 mA

5W FSK 1000 mA 650 mA 500 mA

4W QAM 1800 mA 1200 mA 950 mA

Discrete I/O (per active input or output) 11 mA 7 mA 5 mA

Analog inputs and outputs

(per 20 mA loop)

55 mA 38 mA 30 mA

Connecting a back-up battery to the BAT+ and GNDterminals

You can connect a 13.8 V SLA battery to the BAT+ and GND

terminals to provide a backup power source if the main supply fails.

While the main supply is present, the battery will charge at up to 0.5

A rate until the battery voltage reaches 14.3 V. The battery charger

will then maintain a float charge on the battery at this voltage. To

fully charge the SLA battery, the main supply must be at least 17

Vdc.

When you connect a backup battery, you need to provide sufficient

power to support the additional charge current required when the

battery is discharged (when it is recovering from an extended power

interruption). Table 3 shows the additional current from your power

supply to support battery charging.

Table 3. Additional current to support battery charging

Supply voltage (V

sup

) Current required (I

sup

)

17 Vdc 600 mA

24 Vdc 450 mA

30 Vdc 350 mA

Formula

Powering expansion I/O modules

The 415U modules allow connection of 115S Series modules to

the RS-485 port to provide expanded I/O capacity. You can use the

“+” and “–“ connections on the 415U to provide up to 500 mA

supply for expansion I/O modules. If you have a back-up SLA battery

connected to the 415U, then this connection will also be powered

from the back-up supply, so that the expansion I/O modules receive

the backup power as well as the main module.

ETHERNET

USB RS232 SUPPLY

GND

BAT SUP

SUP

B A

115S-xx 115S-xx

RS-485

B A

B A B A

Figure 7. Expansion I/O power and RS-485

When the module is being powered from the main supply (SUP+

and SUP– terminals), you need to provide sufficient power to

support the additional current required by the expansion I/O

modules. Table 4 shows the additional current from yourpower

supply to support expansion I/O connection.

Table 4. Additional supply current to support expansion I/O

Expansion

I/O

current

exp

)

Current required (I

sup

)

Supply voltage

17 Vdc 24 Vdc 30 Vdc

Base operating current 115S 120 mA 130 mA 90 mA 75 mA

Discrete inputs

(per active input)

13 mA 14 mA 10 mA 8 mA

Discrete outputs

(per active output)

25 mA 27 mA 20 mA 16 mA

Analog inputs and outputs

(per 20 mA loop)

50 mA 55 mA 38 mA 30 mA

Formula

Powering directly from the BAT+ and GNDterminals

In some situations you may want to power the module directly

from a 13.8 Vdc supply. This could be because this voltage supply is

already available at an installation; because the power requirements

for 115S modules are more than can be supplied by the “+” and “–“

expansion I/O connections; or because the installation cannot meet

thermal requirements when being powered from the SUP inputs

(refer to “Thermal” on page 3).

Use Table 5 to determine the device’s current requirements at

13.8 Vdc. Remember you also need to add current for any other

equipment being powered from the same power supply, including

relays, indicators, and any additional 115S modules.

Table 5. Current requirements

Supply current at 13.8 Vdc

Base operating current 180 mA

Radio transmit current

10W FSK 2500 mA

5W FSK 1300 mA

4W QAM 2100 mA

Discrete I/O (per active input or output) 10 mA

Analog inputs and outputs (per 20 mA loop) 50 mA

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Internal I/O

The internal supply voltage register locations shown in the following

table can be monitored using the Diagnostics Web page within the

module’s Web-based configuration utility (see “IO diagnostics” on

page 59 for details). The values can also be mapped to a register

or an analog output on another module within the network.

Table 6. Internal supply voltage registers

30005 Local supply voltage (0–40 V scaling).

30006 Local 24 V loop voltage (0–40 V scaling). Internally generated

+24V supply used for analog loop supply. Maximum current

limit is 100 mA.

30007 Local battery voltage (0–40 V scaling).

30008 115S supply voltage (0–40 V scaling).

38005–38008 Floating point registers that display the actual supply voltage,

battery voltage, +24 V supply, and 115S supply. Note that these

are actual voltage values, whereas registers 30005–30008

display a number between 8192 and 49152 that represents the

voltage scale 0–40 V.

To calculate the supply voltages from the register value use the

following calculation:

Volts = (Register Value) – 8192

1024

High and low voltage alarm indication may be configured for each of

these supply voltages. See “Analog inputs” on page 11 for details

on how to configure these alarms.

Grounding

To provide maximum surge and lightning protection each module

should be effectively earthed/grounded via a GND terminal on the

module. This is to ensure that the surge protection circuits inside the

module are effective. The module should be connected to the same

common ground point as the enclosure ground and the antenna

mast ground.

The 415U and 415U-E have a dedicated earth/ground connection

screw on the bottom end plate next to the supply terminals. All

earth/ground wiring should be minimum 0.8in

(2 mm

), 14 AWG.

If using the 415U with serial expansion I/O modules, all expansion

modules must have a separate earth/ground connection from the

front terminal back to the common earth or ground point.

See Figure 8.

Figure 8. Grounding

Radio

The 415U condor radio uses narrowband radio transmission to

transfer data over licensed radio channels. There are models to

support frequencies in the range 340 MHz to 480 MHz, and to

support narrow (12.5 kHz) and wide (25 kHz) channels.

The 415U-2-C and 415U-E-C module support power levels from

10mW to 10W, and channel bandwidths of 6.25, 12.5 and 25 kHz.

The 415U-2-C and 415U-E-C transmit data using Quadrature

Amplitude Modulation (QAM), with two, four, or six bits per symbol,

supporting data rates up to 96kb/s on a 25kHz channel. The 415U-2C

and 415U-E-C also support FSK modulation for operation with

Legacy 415U-2-H and 415U-2-L models. In Legacy mode, data is

transmitted using direct frequency shift keying with either one or

two bits per symbol (2FSK, 4FSK). This supports data rates of 9600

baud (2FSK) and 19,200 baud (4FSK) on a wide (25 kHz) channel,

and 4800 baud (2FSK) and 9600 baud (4FSK) on a narrow (12.5 kHz)

channel.

ote:N The previous 415U-2 model was available in high powered (415U-2-H

5W radio) and low powered (415U-2-L 500mW radio) configurations.

The radio protocol is based on the 802.11 protocol commonly used

in 2.4 GHz and 5 GHz WiFi applications. If you are familiar with

802.11, many of the radio networking concepts used in the 415 will

also be familiar to you.

The data rates achievable with the 415U are significantly lower than

those for WiFi applications, so care must be taken to make the best

use of the available channel bandwidth.

The 415U module is shipped from the factory without any radio

configuration. The radio will not send any transmission until initial

device provisioning has been completed. At power-up, the device

will set its OK LED to RED to indicate that this initial provisioning

has not been completed.

To configure the device’s radio for the first time, you must configure

the radio Locale and radio Quick Start to set the radio to meet

regulations at its target location. Refer to “Radio” on page 6 for

instructions on configuring the radio using the Configuration utility,

and to “Configuring the locale” on page 45 and “Quick start—

basic device configuration” on page 46 for instructions on how to

configure the radio using the Web interface.

Antennas

Antennas can be either connected directly to the module’s

RFconnector or connected via 50-ohm coaxial cable (such as

RG58Cellfoil or RG213) terminated with a male SMA coaxial

connector. The higher the antenna is mounted, the greater the

transmission range, but as the length of coaxial cable increases

sodo cable losses.

The net gain of an antenna and cable configuration is the gain of the

antenna (in dBi) less the loss in the coaxial cable (in dB). Maximum

net gain for the 415U will depend on the licensing regulation for the

country of operation and the operating frequency.

Typical antennas gains and losses are:

Table 1. Typical antennas gains and losses

Antenna Gain (dBi)

Dipole 2 dBi

Collinear 5 or 8 dBi

Directional (Yagi) 6–15 dBi

Cable type Loss (dB)

RG58 cellfoil cable kits (3 m,10 m, 20 m) –1 dB, –2.5 dB, –4.8 dB

RG213 per 10 m (33 ft) –1.8 dB

LDF4-50 per 10 m (33 ft) –0.5 dB

The net gain of the antenna and cable configuration is determined

by adding the antenna gain and the cable loss. For example, an 8 dBi

antenna with 10 meters of Cellfoil (–2.5 dB) has a net gain of 5.5 dB

(8 dB – 2.5 dB).

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Dipole and Collinear antennas

Dipole and collinear antennas transmit the same amount of radio

power in all directions, and are easy to install and use because they

do not need to be aligned to the destination. The dipole antenna

does not require any additional coaxial cable. However, a cable must

be added if using any of the other collinear or directional antennas.

In order to obtain the maximum range, collinear and dipole antennas

should be mounted vertically, preferably at least one wavelength

away (see Figure 9 for distances) from a wall or mast and at least

3ft (1 m) from the radio module.

Earth Stake

For maximum

range, install

above local

obstructions.

Earth Conductor

at least 5 AWG

(16 mm

)

Wavelength:

340MHz = 35” (88cm)

400MHz = 30” (75cm)

480MHz = 25” (63cm)

Weatherproof

Connections

(recommended:

™

23 self-

bonding tape)

Mast

Coaxial Cable

GND

at least 11 AWG (4 mm

)

Stress

Relief

Loop

Antenna

GND

Surge Arrestor

(recommended)

415U-2

Provide good ground

connection to mast,

module, and surge

arrestor.

If ground conditions

are poor, use more

than one stake.

1 Wavelength

(minimum)

Connect Coax to

building earth in

accordance with

6.2 g) and 6.2 i) of

IEC60728-11:2005

Figure 9. Antennas installation—Collinear/Dipole

Directional antennas

A directional antenna provides high gain in the forward direction,

but lower gain in other directions. This type of antenna may be used

to compensate for coaxial cable loss for installations with marginal

radio path. Directional antennas can be any of the following:

•

Yagi antenna with a main beam and orthogonal elements

•

Directional radome, which is cylindrical in shape

•

Parabolic antenna

Yagi antennas should be installed with the main beam horizontal,

pointing in the forward direction. If the Yagi antenna is transmitting

to a vertically mounted omni-directional antenna, the Yagi elements

should be vertical. If the Yagi is transmitting to another Yagi, the

elements at each end of the wireless link need to be in the same

plane (horizontal or vertical).

Directional radomes should be installed with the central beam

horizontal, and must be pointed exactly in the direction of

transmission to benefit from the gain of the antenna.

Parabolic antennas should be mounted according to the

manufacturer’s instructions, with the parabolic grid at the back and

the radiating element pointing in the direction of the transmission.

Ensure that the antenna mounting bracket is well connected

to ground.

Figure 10. Directional antenna

Installation tips

Connections between the antenna and the coaxial cable should

be carefully taped to prevent ingress of moisture. Moisture

ingress in the coaxial cable is a common cause for problems with

radio systems because it greatly increases the radio losses. We

recommend that the connection be taped—first with a layer of PVC

tape, next with vulcanizing tape (such as 3M™ 23 tape), and finally

with another layer of PVC UV-stabilized insulating tape. The first layer

of tape allows the joint to be easily inspected when troubleshooting

because the vulcanizing seal can be easily removed (see Figure 10).

Where antennas are mounted on elevated masts, the masts should

be effectively grounded to avoid lightning surges. For high lightning

risk areas, approved ELPRO surge suppression devices, such as

the CSD-SMA-2500 or CSD-N-6000, should be fitted between the

module and the antenna. If using non-ELPRO surge suppression

devices, the devices must have a “turn on” voltage of less than 90V.

If the antenna is not already shielded from lightning strike by an

adjacent grounded structure, a lightning rod may be installed above

the antenna to provide shielding.

Figure 10. Vulcanizing tape

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Connections

Bottom panel connections

RJ-45 Ethernet Port

(connects to hub or switch)

USB Port RS-232 Port

ETHERNET USB RS232 SUPPLY

GND

BAT SUP

SUP

B A

Figure 11. Bottom panel connections

Ethernet port

The 415U modules provide a standard RJ-45 Ethernet port compliant

to IEEE 802.3 10/100Base-T. This port provides full access to the

module, including configuration, diagnostics, log file download, and

firmware upload of both the local and remote units. Additionally, the

Ethernet port can provide network connectivity for locally connected

third-party devices with Ethernet functionality.

USB device port for configuration

The 415U modules also provide a USB device (USB-B) connector.

This connector provides configuration of the device and remote

configuration access to other devices in the radio network.

RS-232 port

The 415U modules provide an RS-232 serial port that supports

operation at data rates up to 230,400 baud. This port supports

Modbus protocol. The RS-232 port is accessed using an RJ-45

connector wired as a DCE according to the EIA-562 Electrical

Standard.

Table 2. RJ-45 connector

RJ-45 Signal Required Signal name Connector

1 RI — Ring Indicator

2 DCD — Data Carrier Detect

3 DTR Y Data Terminal Ready

4 GND Y Signal Common

5 RXD Y Receive Data

(frommodule)

6 TXD Y Transmit Data

(tomodule)

7 CTS — Clear to Send

8 RTS — Request to Send

RS-485 port with Modbus support

The 415U modules provide an RS-485 serial port that supports

operations at data rates up to 230,400 baud. The default baud rate is

9600 baud, no parity, 8 data bits and 1 stop bit, which matches the

115S serial expansion module default settings. This port supports the

Modbus protocol.

The RS-485 port terminal is hosted on the four-way expansion

connector on the bottom edge of the module. An on-board RS-485

termination resistor provides line termination for long runs. As a

general rule, termination resistors should be enabled at each end

of the RS-485 cable. When using 115S expansion I/O modules,

remember to enable the RS-485 termination resistor switch that is

located on the end module.

ETHERNET

USB RS232 SUPPLY

GND

BAT SUP

SUP

B A

115S-xx 115S-xx

RS-485

B A

B A B A

Figure 12. RS-485 connections

Side access configuration panel

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A small access panel on the side of the module hides a factory boot

switch, USB host port, and a small bank of DIPswitches that are

used for analog input voltage and current selection, external boot,

and default configuration settings. Use a screw-driver to unscrew

theretained screw to open the access panel.

PWR

232

485

LED Indicator Lights

I/O Connectors

USB Host

Factory Boot

Switch

Conguration

Switches

Side

Access

Panel

Figure 13. Access panel

Factory boot switch

The factory boot switch is used for factory setup and diagnostics.

This switch should only be used if advised by ELPRO

technical support.

USB host port

This port is a USB host (master port) that can interface with

USB storage devices for upgrading the module firmware and for

uploading logged data files. For details, see“To perform a full

firmware upgrade using USB flash drive” on page 77. Also see

“Data logging” on page 62.

DIP switches

The DIP switches are used to select a number of functions within

the module, as shown in the following table.

•

DIP switches 1 to 2—Used for measuring current or voltage

onanalog input 3. Set DIP switches to “on” to measure current

(0–20 mA) and “off” for voltage (0–5 Vdc).

•

DIP switches 3 to 4—Used for measuring current or voltage

onanalog input 4. Set DIP switches to “on” to measure current

(0–20 mA) and “off” for voltage (0–5 Vdc).

•

DIP switch 5—Not used.

•

DIP switch 6—When set to “on” (enabled) and the module is

restarted, the module boots to a recovery mode allowing you

to restore the factory default configuration. See “Restoring the

factory default settings” on page 65.

Note: When the device is powered up whth DIP switch 6 “on,”

radio and I/O functionality isdisabled.

Table 3. Switch functions

Switch Function Current Voltage

DIP 1 and 2 Analog

input 3

DIP 3 and 4 Analog

input 4

Switch Function Disabled Enabled

DIP 5 Not used

DIP 6 Setup mode

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Front panel connections

415U-2 Front Panel Connections

The front panel on the 415U-2 module provides connections for

the following:

•

Eight digital input/output (D1–D8)

•

Two 12-bit, 0.1% accuracy differential analog inputs (AI1, AI2)

•

Two single-ended 12-bit, 0.1% accuracy analog inputs (AI3, AI4)

•

Two 13-bit, 0.1% accuracy current sourcing outputs (AO1, AO2)

•

Connection terminals for common and +24 V analog loop supply

(ALS); maximum ALS current limit is 100 mA

415U-E Front Panel Connections

The 415U-E module provides a subset of the I/O functionality of the

415U-2. Terminals D1 and D2 are provided. Use the GND terminal on

the bottom panel for common connection.

Digital or pulsed inputs

Each digital I/O channel on the 415U modules can act as either

an input or an output. The input/output direction is automatically

determined by the connections and configuration of the I/O. If you

have an I/O channel wired as an input but operate the channel as an

output, no electrical damage will occur but the I/O system will not

operate correctly. If you are operating the channel as an output and

you read the corresponding input value, it will indicate the status of

the output.

Marked D1–8, the digital inputs share the same terminals as the

digital outputs on the 415U-2 module. A digital input is activated by

connecting the input terminal to GND or common, either by voltage-

free contact, TTL level, or transistor switch. Each digital input has

an orange indication LED that will turn on when the input has been

connected to a GND.

Figure 14. Digital/pulsed input wiring

Digital inputs 1–4 can be used as pulsed inputs. The maximum pulse

frequency is 50 kHz for input 1 and 2, and 1kHz for input 3 and 4.

Digital/pulsed inputs are suitable for TTL signal level, NPN-transistor

switch devices, or voltage-free contacts (a relay or switch with

debounce capacitor).

Frequencies greater than 1 kHz you need to use a TTL logic drive or

an external pull-up resistor (1 KΩ to V+). Pulsed inputs are converted

to two different values internally. The first value is the pulse count,

which is an indication of how many times the input has changed

state over a configured time period. The second value is a pulse

rate, which is an analog input derived from the pulse frequency.

Forexample, 0 Hz = 4 mA and 1 kHz = 20 mA.

All pulsed input counts are stored in non-volatile memory, so thatthe

values are saved in the event of a power failure or a modulereset.

Digital outputs (pulsed outputs)

Digital outputs are open-collector transistors, and are able to switch

loads up to 30 Vdc, 200 mA. The eight digital outputs sharethe

same terminals as the digital input. These terminals aremarked D1–8.

Figure 15. Digital pulsed output wiring

When active, the digital outputs provide a transistor switch to

EARTH (Common). To connect a digital output, see Figure 15.

A bypass diode (IN4004) is required to protect against switching

surges for inductive loads such as relay coils. The digital channels

D1–4 on the 415U-2 module (D1-2 on 415U-E) can be used as pulse

outputs with a maximum output frequency of 10 kHz.

Digital output fail-safe status

In addition to indicating the digital output status (on or off), the LEDs

can also indicate a communications failure by flashing the output

LED. This feature can be used by configuring a fail-safe time and

status via the I/O Digital Output screen in the CConfig utility.

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Figure 16. Digital output fail-safe times

The fail-safe time is the time the output counts down before

activating a fail-safe state. Normally this would be configured for

a little more than twice the update time of the mapping that is

sending data to it. This is because the fail-safe timer is restarted

whenever it receives an update. If you send two successive updates

and fail to receive both of these messages, the timer counts down

to zero and activates the fail-safe state.

If the fail-safe state is enabled (on), the LED flashes briefly off and

the digital output turns on. If the fail-safe state is disabled (off), the

LED flashes briefly on and the digital output turns off.

Figure 17. Fail-safe state

Analog inputs

The 415U-2 module provides two floating differential analog inputs

and two grounded single-ended analog inputs. Analog inputs 1 and

2 will automatically measure current (0–20 mA) or voltage (0–25V),

depending on what is connected to the input. Analog inputs 3 and 4

must be configured to measure current (0–20 mA) or voltage (0–5V)

via the DIP switches on the configuration panel (see “Side access

configuration panel” on page 8).

An internal 24 V analog loop supply (ALS) provides power for any

current loops with a maximum current limit of 100mA. The LEDs

have an analog diagnostic function and will indicate the status of the

input. The LED comes ON when any analog signal is detected, and

will go OFF when the analog signal drops to zero.

Note: By default, there is a one-second delay on the input because

of the filter. Filter times can be changed using the Analog Input screen

within the CConfig utility.

The LEDs next to AI1+, AI2+ indicate the current on these inputs.

The LEDs next to AI1– and AI2– indicate the voltage on the

analog inputs.

Differential current inputs

Only analog input 1 and 2 can be wired as differential Inputs.

Differential mode current inputs should be used when measuring a

current loop, which cannot be connected to ground. This allows the

input to be connected anywhere in the current loop. Common mode

voltage can be up to 27 Vdc.

Figure 18 indicates how to connect loop-powered or externally

powered devices to the 415U-2 differential analog inputs. It should

also be noted that the differential inputs can also be used to connect

single-ended current sinking or current sourcing devices. Figure 19

shows how to connect to these types of devices.

Figure 18. Differential current inputs (AI1 and AI2)

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Figure 19. Al1 and Al2 single-ended current inputs

Single-ended current input mode is useful if the sensor loop is

grounded to the 415U-2 module. Devices can be powered from the

24V analog loop supply (ALS) generated internally from the module.

The DIP switches (located in the side access panel) are used to

determine if the inputs will be current or voltage. DIP switches 1

and 2 are used for analog 3, and DIP switches 3 and 4 are used for

analog 4. For current, set both DIP switches to the “on” position.

Forvoltage, set both to “off.”

Figure 20. Al3 and Al4 Single-ended current inputs

Voltage inputs

All analog inputs can be set up to read voltage. If using analog input

1 and 2, connect the voltage source across the positive terminal of

the input and ground. If using analog input 3 and 4, connect across

the input terminal and GND.

Note: Default scaling gives 0–20 V for 0–20 mA output on analog

1 and 2. Default scaling for analog 3and4 gives 0–5 V for 0–20mA

output. For voltage input on analog 3 and 4, set both DIP switches

to the OFF position.

Figure 21. Single-ended voltage inputs

Analog outputs

The 415U-2 module provides two 0–24 mA DC analog outputs for

connecting to analog inputs on equipment (such as PLCs, DCS, and

loggers) or connecting to instrument indicators for displaying remote

analog measurements. The 415U-2 analog outputs are a sourcing

output and should be connected from the analog output terminal

through the device or indicator to ground (GND). See Figure 22 for

connections. The LEDs provide level indication depending on current.

The LEDs appear dimmed for 4 mA and bright for 20 mA.

Figure 22. Analog outputs

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System design

This section covers the topics you should consider when designing

your system. Starting with a sound system design reduces rework

and performance problems during and after commissioning.

Design for failures

All well-designed systems consider system failure. I/O systems

operating on a wire link will fail eventually. Failures can be short-

term, such as interference on the radio channel or power supply

failure, or long-term, such as equipment failure.

The modules provide the following features for system failure:

•

Outputs can reset if they do not receive a message within a

configured time. If an output should receive an update or change

message every 10 minutes and it has not received a message

within this time, some form of failure is likely. If the output

is controlling machinery, it is good design to switch off the

equipment until communications are re-established.

•

The modules provide a fail-safe feature for outputs. This is a

configurable time value for each output. If a message has not

been received for this output within the configured time, the

output will assume a configured value. We suggest that this reset

time be a little more than twice the update time of the input. It

is possible to miss one update message because of short-term

interference. However, if two successive update messages are

missed, long term failure is likely and the output should be reset.

For example, if the input update time is three minutes, set the

output reset time to seven minutes.

•

A module can provide an output that activates on communication

failure to another module. This can be used to provide an external

alarm indicating that there is a system fault.

Redundant Backbone

For systems redundancy is required, you can configure two 415U

modules to operate as a redundant pair.

For maximum reliability you can use the dual-redundant 415U-BSR to

provide a rack mounted redundant solution.

Testing and commissioning

We recommend that the system is fully bench tested before

installation. It is much easier to find configuration problems on

the bench when the modules are next to each other as opposed

to being miles apart. When the system is configured and you are

confident that it works, back up the configurations of all modules.

Networking modes

The 415U series modules support three different radio networking

modes. You select different networking modes depending on your

application. This simplifies your networking configuration.

Fixed Links - Use this for large systems with a fixed repeater

infrastructure and remote sites connecting to the repeater

backbone

ProMesh - This mode automatically assigns stations to act as

repeaters as needed. Use this for smaller flexible networks

where the topology can change due to moving or temporary

repeater locations.

Manual - This mode allows the most flexibility in confiiguring the

network topology, but also more opportunity to mis-configure

the network. This option is only used in rare occasions where

the other two modes can’t meet the network requirements.

ProMesh

ProMesh is the best networking mode to use when it’s not clear

which sites will be repeaters. A ProMesh network consists of a Base

and multiple Mesh Nodes. In a ProMesh network, any Mesh Node

site can act as a repeater to provide a path for other stations to

reach the Base. The ProMesh network automatically configures itself

to a tree structure with the Base station at the root. When a Mesh

Node cannot find a direct connection to the base, It chooses another

Mesh Node to act as a repeater based on the best available path to

the base.

ProMesh networking mode is typically chosen where your radio

environment will be changing, either because the Mesh Nodes are

expected to move, or because the physical environment is expected

to change so much that the same radio paths will not remain

available throughout the lifetime of the network.

Note: You normally configure ProMesh network for operation on a

single radio frequency. Fixed Links or Manual mode networks are more

commonly used where paired frequencies are required. This is because

when frequencies are paired, stations can only connect to repeaters with the

opposite frequency pair (transmit matches receive in both directions).

Figure 23. ProMesh network

User Manual MN032006EN

Effective May 2018

415U Condor-long-range

wireless I/O and gateway

EATON www.eaton.com

Fixed links

•

Fixed Links is the networking mode that is used in the majority

of 415U applications. This mode allows you to configure a tree

structured network with a base station, repeaters, and remotes.

•

You use a fixed links network configuration where you will install

a fixed backbone of repeater stations, with remotes connecting to

one of the repeaters. You can configure the remotes to connect

to a single repeater (Roaming Disabled) or to select the best

repeater to use (Roaming Enabled).

•

Remote stations in the Fixed Links network can be configured

to scan multiple radio frequencies. This allows you to configure

remotes to connect to whichever backbone network it is

closest to, even when the backbone networks are operating on

different frequencies.

Fixed Links networks are suitable for networks where paired

frequencies are required, as it is easy to flip the transmit and receive

frequencies at each repeater.

Figure 24. Fixed Links network with Roaming

Manual mode network

Manual mode networking provides the most flexibility in configuring

how your network connects, but also comes with the greatest risk

of configuring a network that performs poorly or not at all.

Manual mode networking uses the concept of Network Endpoints

which are either Access Point or Client (802.11 networking). Each

client will connect to an access point with matching SSID. Each

access point can accept connections from multiple clients. Each

station has a primary networking endpoint. This is the connection

you define on the main Networking page. You can define additional

endpoints on the Repeaters page to configure additional connections

to other stations in the network.

Note: Behind the scenes, the Fixed Links and ProMesh network modes

use the same concept of Access Point and Client to implement their

networking. The main networking endpoint is always a client, which provides

the upstream connection toward the base, and for repeaters and Mesh

Nodes, an access point provides a second network endpoint for other devices

to connect to.

Internally, all of the networking endpoints are bridged together. This

allows messages to be transferred through the network, but you

need to be careful of causing loops in the network. With Manual

networking mode, there is nothing to stop you creating a loop,

which can cause excessive network traffic as messages are sent

around the loop forever.

If you create networking loops as a way to provide redundant links,

you also need to enable Spanning Tree Protocol, which is designed

to eliminate this type of bridged network loop by imposing a logical

tree structure on the network.

Figure 25. Manual mode networking

User Manual MN032006EN

Effective May 2018

415U Condor-long-range

wireless I/O and gateway

EATON www.eaton.com

IP Address assignment

You should carefully plan how you are going to assign IP addresses

to the devices in your system. By assigning IP addresses in a logical

manner, your network setup will be easier to understand, and the

amount of configuration required will be minimized.

Bridged networks

Most networks will use the Bridged networking mode. This is the

default for the 415U devices. Here the local network of devices

connected to the base, the remote radios, and other devices

connected to the remote radios are all on the same IP subnet.

For this type of network, you should assign a separate block of IP

addresses for remote 415U devices, other remote devices connected

to the 415U radio network, and for any equipment on the local

network at the master station. Assigning IP addresses in this way

allows you to use the Easy Filter configuration to simplify network

filtering. A typical installation could use the following assignment.

Sub-Network Address: 192.168.9.0 (Subnet Mask 255.255.255.0)

(The 192.168.0.xx through 192.168.255.xx addresses are assigned to

private IP networks. This allows up to 254 devices on the

subnetwork.)

Base Network: 192.168.9.1 – 192.168.9.50

(Use addresses in this range for all devices connected to the

Base station network segment, including SCADA computer, PLCs,

Managed Switches, etc.)

415U radio network: 192.168.9.51 – 192.168.9.150

(Use these addresses for the remote 415U devices)

Other Host devices: 192.168.9.151 – 192.168.9.253

(Use these addresses for the devices connected to the Ethernet ports

on the remote 415U devices)

Network traffic control in bridged networks

Bridged networks are convenient to set up because all of the devices

are on a single subnet, and the bridging algorithms take care of

delivering the data packets to the correct destination. One negative

of bridged networking is that any broadcast traffic must be broadcast

over the entire network. This isn’t such a big issue with high speed

Ethernet networks, but with lower speed radio networks, the level

of broadcast traffic on the radio network can stop important traffic

from reaching its destination. Use the Easy Filter option at your

Base Station to ensure that only traffic to the desired destination

IP addresses is forwarded over the radio network. Easy Filter filters

out any non-IP traffic, and any IP traffic to addresses outside the

configured range.

Using the example above, you should configure Easy Filter at your

Base Station to cover the “415U radio network” and the “Other Host

devices”, but not the “Base Network”.

Figure 26. Easy filter

Routed networks

Sometimes it is necessary to configure the radio as an IP router to

support desired addressing or address segmentation.

For this type of network, you need to assign different separate

subnetwork addresses to each Sub-network. Normally you set the

415U Base station as an IP Router, and configure the Base Network

on one subnetwork, and all remote devices on another subnetwork. A

typical installation could use the following assignment.

Base Subnetwork:

Sub-Network Address: 192.168.9.0 (Subnet Mask 255.255.255.0)

Base Network: 192.168.9.1 – 192.168.9.100

Base Station 415U Ethernet IP address: 192.168.9.101

Remote Subnetwork:

Sub-Network Address: 192.168.10.0 (Subnet Mask 255.255.255.0)

415U radio network: 192.168.10.2 – 192.168.10.100

(Use these addresses for the remote 415U devices)

Other Host devices: 192.168.9.101 – 192.168.9.253

(Use these addresses for the devices connected to the Ethernet ports

on the remote 415U devices)

Base Station 415U Radio IP address: 192.168.10.1

Note that in this configuration the remote 415 devices are still

configured for Bridging. If you configure the remote 415 devices

for routing, then you need to assign a separate subnetwork and

separate Ethernet IP addresses for the local Ethernet network at

each remote

415 device.

The PC Based Configuration Utility CConfig does not support Routed

network configuration. You can only configure Routed mode using

the Web based configuration interface. See “Configuring using the

embedded Web Configuration Utility” on page 49

Routing rules

When you configure your Base station as an IP Router (Basic

Provisioning >> Network >> Network Mode >> Router) you also

configure a different IP subnet on the radio and on the Ethernet

port. To allow messages to pass through the router, you need to

set up routing rules to tell the remote devices (Remote 415U, Base

Computer, and other remote Connected device) to use the Base

station 415U as the router to reach the remote device.

Using the example above, at your Scada PC, you need to add a

routing rule to use the Base Station Ethernet IP address to reach the

192.168.10.0 network:

> route ADD 192.168.10.0 MASK 255.255.255.0 192.168.9.101

And at your remote 415 units, you need to add a routing rule to use

the Base Station Radio IP address to reach the 192.168.9.0 network

(Advanced Networking >> IP Routing ):

ote:N You will need to add similar routing rules to any other devices you have

connected to the Ethernet ports on the remote 415 devices which need to

communicate back to the Base network.

User Manual MN032006EN

Effective May 2018

415U Condor-long-range

wireless I/O and gateway

EATON www.eaton.com

Radio Paths and Data Rate

A critical element in system design is to ensure that the radio signals

are able to reach their destination reliably. This section provides

guidance on configuring your devices to deliver data reliably.

Modulation Type and Data Rate

The 415U supports two modulation types (Legacy FSK and High

Speed QAM), and a total of six data encodings (two for FSK, and

four for QAM modulation). The availalble data rates depend on the

modulation type, the encoding, and the radio bandwidth. Faster data

rates allow more data to be transferred in your system, but require a

clearer signal to get through.

The following table shows the available data encodings and raw data

rate for the available radio band-width settings.

Modulation type

and encoding

Raw Data Rate

QAM 25kHz channel 12.5kHz channel 6.25kHz channel

4QAM + FEC 16kbps 8kbps 4kbps

4QAM 32kbps 16kbps 8kbps

16QAM 64kbps 32kbps 16kbps

64QAM 96kbps 48kbps 24kbps

FSK

2FSK 9.6kbps 4.8kbps 2.4kbps

4FSK 19.2kbps 9.6kbps 4.8kbps

The following table shows the available data encodings and required

signal strangth for reliable reception (Bit error rate 1 in 100,000). The

system figure shows the maximum path loss after accounting for

antenna system gains or losses. (Transmit Power minus Sensitivity)

QAM Modulation

encoding

Sensitivity (BER

-5

)

Maximum

Transmit Power

Maximum System

Figure

4QAM + FEC -116 dBm +36dBm 152dB

4QAM -113 d Bm +36dBM 149dB

16QAM -104 dBm +34dBm 138dB

64QAM -97 dBm +34dBm 131dB

FSK Modulation

encoding

2FSK -110 dBm +40 dBm 150dB

4FSK -102 dBm +40 dBm 142dB

When designing your radio network, you calculate the system figure

to determine what data rate you are likely to achieve between two

sites. You calculate the system figure by adding the transmitter

power and antenna gain, and subtracting co-axial cable losses and

path loss between the two sites.

Auto Rate

The 415U modules support automatic data rate selection. This is

normally the best option, as the modules will set the data rate to

the maximum according to the signal strength, and will then adjust

the data rate if the signal strength reduces (due to changing path

conditions, or degrading antenna systems), or if too many messages

are corrupted during transmission (due to interference)

The default setting for the 415U modules is auto rate. This is

appropriate for the majority of situations, however the automatic

rate selection can struggle to find a consistent rate if there is local

interference, if the system is so busy that many messages fail to be

delivered, or if the two ends of the link are configured with different

power levels. In these cases, you could see improved performance

by setting the module transmit data rate (Radio Configuration Page)

Where you have a very remote site, you might need to use a high

gain directional antenna (Yagi) to reach your repeater or base station.

To stay inside the radio license requirements, you may need to

reduce the transmit power to compensate for the antenna gain at

that remote site. If the transmit power at each end of a link differs

by more than 3dB, you should disable Auto Rate, and select the best

fixed rate for that site.

Basic Rate

In addition to the Data Rate, each radio in your system.is configured

with a basic rate. This is the lowest rate that any radio in the system

can communicate at. The default value for the basic rate is 4QAM

(for High speed mode) or 2FSK (for Legacy Mode). All radios must

be configured with the same basic rate.setting.

Where all of the radio paths in the system have good signal

strength, you can set the basic rate to a higer value to achieve

increased system througput (Radio Configuration Page). If you have

some radio paths which may require the strongest encoding (FEC)

to operate, you should set the basic rate to the lowest rate (4QAM

+ FEC).

The basic rate is used for transmissions during link establishment,

as well as for beacon messages and for broadcast transmissions.

The basic rate also affects the radio channel delays (hold-off times),

as the radio access protocol needs to allow for the possibility of low

speed transmissions when the basic rate is lower. This means that a

system with a lower basic rate will experience lower througput, even

if the actual data rates between the sites are the same.

Note: Radios are able to communicate with each other when the basic

rate is set to different FSK or QAM encoding (without FEC), but this is not

recommended, as the channel access timing is different, and this is likely to

result in more message corruptions due to overlapping transmissions .

Forward Error Correction

The High Speed (QAM) modulation type provides an additional

encoding mode to provide the best possible long range

performance. 4QAM+FEC mode applies forward error correction to

the 4QAM signal. This adds additional data bits to the transmitted

messaage that can be used at the receiving end to recover data that

was corrupted during data transmission. This mode provides a low

speed option to allow operation over the longest distances.

Note: The default basic rate setting is 4QAM without FEC. If you think

your system will need this mode, then you need to select the 4QAM+FEC

data rate as your Basic Rate setting for all radios in your system.

Transmit Power Setting.

You should set your transmit power according to your radio license.

If you have configured the radio for an unlicensed / class licensed

locale then your power level setting will be limited to the maximum

allowed for your locale. In either case, you need to account for the

gain of your antenna system to ensure you are not exceeding the

allowed radiated power level.

Most radio licenses are based on average transmit power, however

some specify peak power levels. For Legacy FSK transmission, the

average and peak power are the same, but for High Speed QAM

transmission, the average and peak powers are different. The power

setting that you make sets the target average power, but at some

target power levels the radio is limited by it’s peak power capability.

Check the peak and average power available in QAM modes

according to the table below. The highlightged cells show where the

average power has been limited to less than the requested value by

the radio peak power capability

Peak Power (Watts) Average Power (Watts)

Power Setting 4QAM

(incFEC)

16QAM 64QAM 4QAM

(incFEC)

16QAM

64QAM

2FSK

4FSK

40dBm (10W) 13.2W 12.1W 13.5W 4W 2.5W 10W

39dBm (8W) 13.2W 12.1W 13.5W 4W 2.5W 8W

38dBm (6.3W) 13.2W 12.1W 13.5W 4W 2.5W 6.3W

37dBm (5W ) 13.2W 12.1W 13.5W 4W 2.5W 5W

36dBm (4W) 13.2W 12.1W 13.5W 4W 2.5W 4W

35dBm (3.2W) 10.5W 12.1W 13.5W 3.2W 2.5W 3.2W

34dBm (2.5W) 8.3W 12.1W 13.5W 2.5W 2.5W 2.5W

33dBm (2W) 6.6W 9.55W 10.8W 2W 2W 2W

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ELPRO 415U-2 User manual

Brand: ELPRO

Model: 415U-2

Category: Networking

Type: User manual

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